Influence of process parameters on thickness-radius ratio of cross-wedge rolling of laminated shaft of 42CrMo/Q235 composites

By using ANSYS/LS-DYNA software, the finite element(FE) model of cross-wedge rolling of laminated shafts was established. Some thickness-radius ratio rolling experiments were carried out under the orthogonal experimental designed with four factors and three levels. Through finite element simulation, the effect of process parameters including forming angle, spreading angle, area reduction and rolling temperature on thickness-radius ratio were analyzed. The results show that the rolling experimental results accord with the simulation results, which shows that finite element model can be used to predict thickness-radius ratio. With the increase of spreading angle, the thickness-radius ratio sharply decreases first and then slowly decreases. With the increase of temperature, the thickness-radius ratio strengthens first and then slowly strengthens. With the increase of area reduction, the thickness-radius ratio slowly strengthens first and then changes little. With the increase of forming angle, the thickness-radius ratio change is not obvious. The influencing sequence on the thickness-radius ratio is spreading angle, rolling temperature, area reduction and forming angle in turn. The research results contribute to control and design clad material thickness and matrix material radius size of laminated shaft.